Failure Modes and Effects Analysis (FMEA) & Root Cause Analysis

Overview

Failure Modes and Effects Analysis: FMEA is a logical process based methodology for identifying all possible failures in process or product. It can be applied to services and business processes as well as product design and manufacturing processes.

A properly executed FMEA should result in corrective actions to address failures that have been observed as well as preventive actions to enable avoidance of potential failure modes that have been discovered.

Gain a working knowledge of the FMEA process for products, processes, or systems in this one-day class. A failure modes and effects analysis (FMEA) helps analyze a proposed or existing process or product to uncover potential failures within the product, process, or system before they occur. The introductions and hands-on classes will teach you how to construct and analyze both product and process FMEAs.

Root Cause Analysis: Don’t just put a bandage on a problem – fix it permanently. A root cause is the fundamental, underlying reason for a problem. Root Cause Analysis is an approach for identifying the underlying causes of why an incident occurred so that the most effective solutions can be identified and implemented. This class enables you to define your problem, identify the cause of the problem, solve it, and prevent it from occurring again.

Target Audience

Anyone involved in identifying and reducing risk

Design engineers

Process owners or process engineers

Those in quality assurance

Research and Development personnel

Individuals responsible for new product introduction

Quality, safety, risk, and reliability managers

Operations supervisors

And anyone who wants to improve their ability to solve recurring problems should attend this training

Prerequisites

Engineering or Manufacturing experience recommended

Duration

2 day

Venues

Classroom, Onsite

Price

$1200

Learning Objectives

Day 1 FMEA:

Define the types of FMEAs

Identify the benefits of FMEAs

Understand the components of a FMEA

Describe process requirements

Explain the impact of team selection on the FMEA

Manage the FMEA over the life of the process

Day 2 Root Cause Analysis:

How to clearly define the problem

How to characterize the process where the problem is

When to use anecdotal evidence and when to use hard data

How to develop a sampling strategy and collect data

Several analytical tools and when each is most appropriate

Strategies to improve processes and prevent recurrence of the root cause

Course Content

Day 1 FMEA:

Introduction to Failure Mode Effects Analysis (FMEA) – One (1) Hour

Format: WebEx – generally presented as a Lunch & Learn

Tools: Interactive A/V presentation and dialogue

Deliverables: An introduction to FMEA and how to get the most value from them.

Outcomes: Awareness and understanding of how to apply FMEA and potential to plan for an effective training and deployment plan for your organization.

How to Perform a Process FMEA – Two (2) Hours (FMEA Intro)

Format: WebEx

Tools: Interactive A/V presentation and dialogue

Deliverables: Basic training in application and deployment of process FMEA.

Outcomes: Participants will be capable of performing a process FMEA. They will also understand the requirements and competencies required to perform a process FMEA to facilitate planning for who should participate in your organization.

Deliverables: Complete training and skill development on the creation of process & design FMEAs.

Outcomes: Participants will be capable of performing a process & design FMEA. They will also understand the requirements and competencies necessary to perform a process FMEA and help facilitate planning for who should participate in your organization.

FMEA Hands on Project Application – One (1) Day (FMEA P/A)

Format: Optional 2nd day offered in conjunction with (3a) working with the same 10-20 participants

Tools: Existing failures identified from previous day, FMEA templates

Deliverables: Completed FMEAs. Applied training for participants on live examples.

Outcomes: Corrective action plans resulting from completing FMEAs. Participants will have the skills and experience in completing FMEAs in a live environment.